FIELD OF THE INVENTION
This invention relates generally to a light weight container, and more particularly, to a lightweight container having interlocking capabilities.
BACKGROUND OF THE INVENTION
The postal service receives millions of pieces of mail every day. This mail is then sorted and transported to the various destinations. Generally, the sorting process involves placing mail with the same general destinations into trays. The trays may be placed on pallets, which are loaded on trucks or other vehicles for transportation to the appropriate destinations. The pallets, on which the trays are placed and transported, may be lightweight and flexible enough that column-stacked trays are unstable when lifted by a fork truck.
Historically, the stability of a pallet loaded with trays has been established by stretch wrapping or strapping the columns of stacked trays to the pallet. However, stretch-wrapping or strapping the trays to the pallets increases the time and labor associated with the transporting process. In addition, the materials required to stretch-wrap or strap the trays to the pallet increase the material cost associated with the transporting process.
It is accordingly a primary object of the invention to provide a lightweight tray with interlocking capabilities that minimizes or eliminates the need for binding a load of column-stacked trays to a pallet before loading and transporting of the load.
SUMMARY OF THE INVENTION
In one aspect, the present disclosure is directed to a container having a tray and a lid. The tray includes a base, two side panels connected along one edge to the base, and two end panels connected along one edge to the base and along one edge to each of the side panels. The lid is configured to engage the tray. The tray and the lid each include at least one of protrusions and recesses configured to restrict lateral movement of the lid of the container relative to the tray of another substantially identical container.
In another aspect, the present disclosure is directed to a method of stacking containers. The method includes positioning a first layer of containers, each having a tray and a lid. The lid includes one of protrusions and recesses. The method further includes positioning a second layer of containers on top of the first layer of containers, each of the second layer of containers having a tray and a lid. The tray of the second layer of containers includes the other of protrusions and recesses. The other of protrusions and recesses of the second layer of containers engage the one of protrusions and recesses of the first layer of containers to restrict lateral movement of the second layer of containers relative to the first layer of containers.
Additional objects and advantages of the invention will be set forth in part in the description, which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view diagrammatic illustration of a container according to an exemplary embodiment of the present invention
FIG. 2A is a bottom view diagrammatic illustration of a tray of a container according to an exemplary embodiment of the present invention;
FIG. 2B is a front view diagrammatic illustration of a tray of a container according to an exemplary embodiment of the present invention;
FIG. 2C is an end view diagrammatic illustration of a tray of a container according to an exemplary embodiment of the present invention;
FIG. 2D is a cross-section view illustration of a label holder according to an exemplary embodiment of the present invention;
FIG. 3A is a top view diagrammatic illustration of a lid of a container according to an exemplary embodiment of the present invention;
FIG. 3B is a front view diagrammatic illustration of a lid of a container according to an exemplary embodiment of the present invention;
FIG. 3C is an end view diagrammatic illustration of a lid of a container according to an exemplary embodiment of the present invention;
FIG. 4A is schematic illustration of an interlocking position of two containers according to an exemplary embodiment of the present invention;
FIG. 4B is schematic illustration of an interlocking position of two containers according to an exemplary embodiment of the present invention;
FIG. 4C is schematic illustration of an interlocking position of two containers according to an exemplary embodiment of the present invention;
FIG. 4D is schematic illustration of an interlocking position of two containers according to an exemplary embodiment of the present invention;
FIG. 4E is schematic illustration of an interlocking position of two containers according to an exemplary embodiment of the present invention;
FIG. 5 is schematic illustration of a positioning pattern of containers according to an exemplary embodiment of the present invention; and
FIG. 6 is schematic illustration of a positioning pattern of containers according to an exemplary embodiment of the present invention.
DESCRIPTION OF THE EMBODIMENTS
Detailed Description
Reference will now be made in detail to the present exemplary embodiments of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
FIG. 1 illustrates an exemplary embodiment of a container 10. Container 10 may include a lid 12 and a tray 14. Lid 12 may be configured to engage tray 14 to complete an enclosure. Lid 12 may or may not include a locking mechanism that secures lid 12 to tray 14. Lid 12 may be separate from tray 14 or hinged to tray 14. Container 10 may be formed from a polyolefin material such as, for example, polypropylene or polyethylene. Alternately, container 10 may be formed from a material other than polyolefin such as ABS (Acrylonitrile Butadiene Styrene), aluminum, or any other suitable material that provides a lightweight protection for the contents of container 10.
As illustrated in FIGS. 2A-2C, tray 14 may include a base 16, two side panels 18, two end panels 20, and a curved rim 22. Each of side and end panels 18 and 20 may be connected to base 16 along one edge. In addition, each side panel 18 may be connected to each end panel 20 along one edge. Curved rim 22 may be disposed along an upper outer periphery of tray 14 and connected to side and end panels 18 and 20. Base 16, side panels 18, end panels 20, and curved rim 22 may be a single integral part formed through an injection molding process, a thermo-forming process, a blow molding process, or through any other appropriate forming or molding process known in the art. It is also contemplated that some or all of the parts may be formed separately and joined together through a fabrication process.
Base 16 may be a planar rectangular-shaped part having a length direction and a width direction. It is also contemplated that base 16 may have a shape other than rectangular such as, for example, square or any other shape known in the art.
Base 16 may include one or more channels 24. Channels 24 may be linearly disposed on a bottom surface 28 of base 16 in the width direction. Channels 24 may extend through base 16 and result in projections from a top surface 30 of base 16, as depicted in FIGS. 2A and 2B. It is also contemplated that channels 24 only extend a portion of the distance through base 16. It is contemplated that there may be more or fewer of channels 24 than those depicted in FIGS. 2A and 2B, and that channels 24 may extend in the length direction rather than the width direction. It is also contemplated that base 16 may include channels in both the width and length direction or that channels 24 may be absent from base 16 and only included in lid 12, as will be described below. Channels 24 may be configured to retain container securing straps (not shown) in a predetermined position relative to container 10. It is contemplated that another means for retaining the container securing straps may be implemented such as, for example, loops, projections, or another means known in the art.
Base 16 may also include one or more positioning recesses 26. The positioning recesses 26 may be disposed in bottom surface 28 of base 16. Recesses 26 may extend through base 16 and result in projections from top surface 30 of base 16, as depicted in FIGS. 2A and 2B. It is also contemplated that recesses 26 only extend a portion of the distance through base 16. Recesses 26 may each have a circular, square, L-shaped, rectangular, or any other appropriate cross-sectional shape known in the art. It is further contemplated that recesses 26 may be absent and projections included. Recesses 26 may be disposed in rows 32 and columns 34 after a particular pattern. As illustrated in FIG. 2A, the distance between rows 32 and columns 34 of recesses 26 may be equal. It is also contemplated that there may be a greater or lesser number of rows 32 and columns 34, that recesses 26 may be disposed in another pattern other than rows 32 and columns 34, and that the spacing between recesses 26 may or may not be equal.
Base 16 may include one or more protrusions 35 extending from either end of base 16. The pattern of protrusions extending from one end of base 16 may be different from the pattern of protrusions extending from the opposite end of base 16. The different patterns of protrusions 35 may facilitate nesting of one tray 14 within another substantially identical tray 14 when the two trays 14 are aligned, and stacking of the trays 14 when oriented 180 degrees from each other. It is contemplated that a different number of protrusions 35 than depicted in FIG. 2A may be included within base 16. It is further contemplated that the same pattern of protrusions 35 may extend from both ends of base 16 or that protrusions 35 may be absent, if desired.
As illustrated in FIG. 2B, side panels 18 may be planar trapezoidal-shaped parts having a first length generally equal to that of base 16 and a second length greater than the first. A width dimension, between the two parallel edges of side panels 18, may be less than both the first and second lengths. It is also contemplated that the width dimension may be greater than the first and second length dimensions and that side panels 18 may have another shape other than trapezoidal. The trapezoidal shape of side panels 18, as well as end panels 20, as discussed below, may facilitate nesting of tray 14 within another identical tray 14.
Each of side panels 18 may include vertical corrugations 40 longitudinally extended in the width direction. Each of corrugations 40 may extend through both an inner surface 41 and outer surface 43 of each side panel 18 (referring to FIG. 2A). Alternately, corrugations 40 may only extend through one of inner and outer surfaces 41 or 43, or may be disposed between inner and outer surfaces 41 and 43. Corrugations 40 may be continuous along side panel 18 or may, alternately, include interrupted sections of corrugations. Corrugations 40 may extend from a bottom edge 45 of each side panel 18 to a top edge 47 of each side panel 18. It is contemplated that corrugations 40 may or may not begin and end on an edge of respective side panels 18, and that corrugations 40 may or may not be orthogonal to the bottom and top edges 45, 47. Corrugations 40 may be configured to add strength to container 10 vertically and/or transversely. It is also contemplated that corrugations 40 may be absent and another means for strengthening container 10 present such as, for example, reinforcement members, creases, or another means for strengthening known in the art.
FIG. 2C illustrates end panels 20 as being planar trapezoidal-shaped parts having a first length generally equal to the width of base 16 and a second length greater than the first. The width of end panels 20 may be generally equal to the width of side panels 18.
Each of end panels 20 may include a corrugated section 36. Corrugated section 36 may include two sets of corrugations 40a and 40b longitudinally extended in the width direction. Each of corrugations 40 may extend through both an inner surface 42 and an outer surface 44 of each end panel 20 (referring to FIG. 2A). Alternately, corrugations 40 may only extend through one of inner and outer surfaces 42 or 44, or may be disposed between inner and outer surfaces 42 and 44. One set of corrugations 40a may be angled towards the other set of corrugations 40b and may extend from a bottom edge 46 of each end panel 20 to a top edge 48 of each end panel 20. It is contemplated that corrugations 40 may or may not begin and end on an edge of respective end panels 20, and that corrugations 40 may or may not be angled. Corrugations 40 may be configured to add strength to container 10 vertically and/or transversely. It is also contemplated that corrugations 40 may be absent and another means for strengthening container 10 present such as, for example, reinforcement members, creases, or another means for strengthening known in the art.
Each of end panels 20 may also include one or more nesting stops 38. Nesting stops 38 may be protrusions extending outward from an outer surface of end panels 20. Nesting stops 38 may be configured to abut curved rim 22 of a second container when tray 14 is inserted into the second container to thereby limit an engagement depth of tray 14 within the second container. It is contemplated that a greater or lesser number of nesting stops 38 may be included and that nesting stops 38 may alternately be disposed on side panels 18. It is also contemplated that another means for limiting the engagement depth of tray 14 within the second container may be implemented. These other means for limiting the engagement depth may include, for example, a stop protruding from bottom surface 28 of base 16, a stop protruding from top surface 30 of base 16, a rim disposed on an outer periphery of tray 14, or others as known in the art.
As illustrated in FIGS. 2C and 2D, one or both of end panels 20 may include a label holder 50 generally centrally positioned on outer surface 44. Label holder 50 may be a snap-in type label holder having a recessed portion 50a, and two retaining portions 50b. A flexible label 52 may be pressed into recessed portion 50a and retained in position by retaining portion 50b. It is also contemplated that label holder 50 may be absent from end panels 20 and included in side panels 18 or in tray 14.
As described above and illustrated in FIGS. 2A-2C, curved rim 22 may be disposed along an upper outer periphery of tray 14 relative to base 16 and connected to side and end panels 18 and 20. Curved rim 22 may include an angled portion 56 extending at variable distances away from side and end panels 18 and 20. Curved rim 22 may be configured to provide support to an upper portion of tray 14 and provide a means for grasping container 10. In particular, curved rim 22 may include a handle portion 58 located at each end of tray 14, adjacent end panels 20. Handle portion 58 may allow access from both the top and bottom of container 10 and may be in the form of a bar secured within rim 22. It is also contemplated that another means for grasping container 10 may be included such as, for example, projections or recesses located midway on side and/or end panels 18 and 20, projections or recesses located on base 16, a central projection or recess located on a lid secured to tray 14, or other means known in the art. Curved rim 22 may also include one or more pinch portions 59. Pinch portions 59 may connect a lower outer edge of angled portion 56 to end panels 20 to provide support to angle portion 56.
As illustrated in FIGS. 3A-3C, lid 12 may include a main portion 60 and a peripheral portion 62. Peripheral portion 62 may be connected to main portion 60 along an entire perimeter of main portion 60 and may have a similar overall shape as rim 22 of tray 14 so that lid 12 fits on an upper surface of rim 22. Main portion 60 and peripheral portion 62 may be a single integral part created through a forming or molding process. Alternately, each part may be formed separately and joined together through a fabrication process.
Main portion 60 may be a planar rectangular-shaped part having a length direction and a width direction. It is also contemplated that main portion 60 may have another shape such as, for example, square, circular, or any other shape known in the art. Main portion 60 may include one or more channels 64 and one or more positioning projections 66.
Channels 64 may be linearly disposed on a top surface 68 of main portion 60 in the width direction, aligned with channels 24 in base 16 of tray 14. Channels 64 may extend through base 16 and result in projections from a bottom surface 70 of main portion 60. It is contemplated that channels 64 may only extend a fraction of a distance through main portion 60. It is also contemplated that there may be a greater or lesser number of channels 64 than those depicted in FIGS. 3A and 3B, and that channels 64 may extend in the length direction rather than the width direction. It is further contemplated that main portion 60 may include channels 64 in both the width and length directions, or that channels 64 may be absent and only channels 24 in base 16 included. As explained above, channels 64 may be configured to retain container securing straps in a predetermined position relative to container 10.
Projections 66 may include multiple projections disposed in main portion 60 of lid 12. Projections 66 may have a circular, square, L-shaped, rectangular, or any other appropriate cross-section known in the art. Projections 66 may be configured to be received within recesses 26 of tray 14 to restrict motion of container 10 relative to another substantially identical container 10, when containers 10 are stacked one on top of the other. As described above, it is contemplated that base 16 may alternately have projections. In this situation, projections 66 in the lid may be absent and recesses included. Alternately, both tray 14 and lid 12 may include projections that interact to restrict motion of one container 10 relative to another container 10, when containers 10 are stacked one on top of another
Projections 66 in lid 12 may be disposed in rows 32 and columns 34 after a predetermined pattern. As illustrated in FIG. 3A, the distance between rows 32 and columns 34 of projections 66 may be equal. In addition, the pattern of rows 32 and columns 34 of projections 66 in lid 12 may be substantially the same as the pattern of rows 32 and columns 34 of recesses 26 in base 16. It is contemplated that projections 66 may be disposed in another pattern other than rows 32 and columns 34, that there may be a greater or lesser number of rows 32 and columns 34, that the spacing between projections 66 may or may not be equal, and that the pattern of projections 66 in lid 12 may be different than the pattern of recesses 26 in tray 14.
Peripheral portion 62 may have a substantially constant cross-section and an inner surface 72 configured to mate against angled portion 56 of curved rim 22. Alternately, peripheral portion 62 may have a variable cross-section.
FIGS. 4A-4E illustrate available vertical stacking arrangements of one exemplary container 10 relative to another. FIGS. 5-6 illustrate available stacking patterns for layers of exemplary containers 10 on a pallet 74. These figures will be discussed in the following section to further illustrate the disclosed invention.
INDUSTRIAL APPLICABILITY
The disclosed container 10 may provide a lightweight sturdy support structure and environmental protection for its contents. Tray 14 of container 10 may be nestable, stackable, and interlockable with other substantially identical trays 14. In addition, container 10 may reduce or eliminate the need to stretch-wrap or strap containers 10 to a pallet 74 before handling or loading of pallet 74, may provide for secure placement of individual container retention straps, may provide for snap-in placement of a label, and may prevent binding of one container 10 relative to another when nested. As a result, container 10 and a method of stacking and interlocking trays 14 may reduce the material cost, time, and labor typically associated with handling, loading, and transporting of conventional containers.
As described above, tray 14 may be nested and stacked within a second identical tray 14 when lid 12 is removed from the lower tray 14. Nesting is the loading of a portion of one tray 14 inside of another to either reduce the space displaced the trays 14 or to make empty containers 10 easier to transport. Tray 14 of one container 10 may be nested within the tray 14 of another container 10 in a first orientation where the longitudinal directions of the two containers 10 are aligned, and may be blocked from nesting by protrusions 35 in a second orientation that is rotated 180° relative to the first orientation. When blocked from nesting, the two containers 10 may be stacked one on top of the other, with the base of the upper container 10 retained within rim 22 of the lower container to limit relative movement between the two containers without closing the lid 12 of the lower container. It is contemplated that container 10 may alternately be nestable in both the first and second orientations.
The engagement depth that a first container 10 is nested within a second container 10 may be limited to minimize the likelihood of separation difficulty. As also described above, nesting stops 38 may be provided on the first container 10 that are configured to engage curved rim 22 of the second container 10, within which the first container 10 is nested to limit engagement depth. In this manner, containers 10 may be nested without the associated risk of binding relative to each other that hinders separation.
As illustrated in FIGS. 4A-4E, containers 10 may be interlocked in a number of ways because of the equally spaced pattern of projection and recess rows 32 and columns 34. FIG. 4A shows two containers 10 longitudinally aligned, with an upper container 10 offset from a lower container 10 in a longitudinal direction. In FIG. 4A, one row 32 of projections 66 (two projections total) from the lower container lid 12 engage one row 32 of recesses 26 in base 16 of the upper container 10. FIG. 4B also shows two containers 10 longitudinally aligned, but with the upper container 10 offset from the lower container 10 in a transverse direction. In FIG. 4B, a longitudinal column 34 of projections 66 (three projections total) from the lower container lid 12 engage a column 34 of recesses 66 in base 16 of the upper container 10, with the containers offset widthwise. FIG. 4C shows two containers 10 orthogonally disposed relative to the longitudinal directions of each container 10. In FIG. 4C, two rows 32 of projections 66 (four projections total) from the lower container 10 engage two rows 32 of recesses 66 from each column 34 in base 16 of the upper container 10. FIG. 4D, similar to FIG. 4C, shows two orthogonal containers 10, but with only one row 32 of projections 66 (two projections total) from the lower container 10 engaging two recesses 26 from one column 34 in base 16 of the upper container 10. FIG. 4E again shows two orthogonal containers 10, but with only one projection 66 from the lower container 10 engaged with one recess 26 in base 16 of the upper container 10. It is contemplated that other interlocking arrangements may be made, and that greater or fewer projections 66 and recesses 26 may be engaged.
As illustrated in FIGS. 5-6, different patterns for layers of containers 10 stacked on pallets 74. A typical lightweight pallet may have the general dimensions of three feet wide and four feet long. Alternate embodiments may includes pallets one-half to one-third these dimensions as well. Containers 10 may have a length generally two-fifths the length of pallet 74 and a width generally one third the width of pallet 74. Other relationships of container width and length to pallet width and length are also contemplated. Typical layers of generally comprise eight containers 10 per layer, and may be arranged differently to accommodate different load requirements.
FIG. 5 shows a pattern A having all eight containers 10 longitudinally aligned in a single direction, with two columns of four containers 10 each. FIG. 6 shows a pattern B having three rows of containers 10 including two outside rows that are longitudinally aligned in a first direction and one inside row longitudinally aligned in a second direction that is orthogonal to the first direction. Alternately, the inside row may be longitudinally aligned in the first direction and the outside row aligned in the second direction.
Different layers of containers 10 stacked on the same pallet 74 may have different patterns. For example, a first layer may be stacked after pattern A and a second layer stacked after pattern B. Alternately, a first layer may be stacked after pattern A and a second layer stacked after pattern C. In addition, a first layer may be stacked after pattern B and a second pattern stacked after pattern C. Further, a first and a second layer may be stacked after only pattern A, only pattern B, or only pattern C. It is also contemplated that the pattern of one layer may be rotated a number of different ways relative to a second layer.
Other embodiments of the disclosed container will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. For example, the containers may be a different shape, they may have different interlocking mechanisms, and there may be multiple shapes and sizes of containers configured to stack, interlock, and nest within each other. It is also contemplated that other patterns of layering containers may be implemented, that all of the patterns within a pallet load may have the same pattern, that all patterns with the same pallet load may have different patterns, or that the patterns may involve containers of different sizes and shapes. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
Patent Application
20050224386
